WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels: A Prerequisite for the High Heat-Transfer Rate
To get the maximum heat transfer in real applications, the surface area of the micro-features (micro-channels) needs to be large as possible. It can be achieved by producing a maximum number of micro-channels per unit area. Since each successive pair of the micro-channels contain an inter-channels f...
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| Format: | Article |
| Language: | English |
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MDPI AG
2020-02-01
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| Series: | Micromachines |
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| Online Access: | https://www.mdpi.com/2072-666X/11/2/173 |
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| author | Naveed Ahmed Mohammad Pervez Mughal Waqar Shoaib Syed Farhan Raza Abdulrhman M. Alahmari |
| author_facet | Naveed Ahmed Mohammad Pervez Mughal Waqar Shoaib Syed Farhan Raza Abdulrhman M. Alahmari |
| author_sort | Naveed Ahmed |
| collection | DOAJ |
| description | To get the maximum heat transfer in real applications, the surface area of the micro-features (micro-channels) needs to be large as possible. It can be achieved by producing a maximum number of micro-channels per unit area. Since each successive pair of the micro-channels contain an inter-channels fin, therefore the inter-channels fin thickness (IFT) plays a pivotal role in determining the number of micro-channels to be produced in the given area. During machining, the fabrication of deep micro-channels is a challenge. Wire-cut electrical discharge machining (EDM) could be a viable alternative to fabricate deep micro-channels with thin inter-channels fins (higher aspect ratio) resulting in larger surface area. In this research, minimum IFT and the corresponding machining conditions have been sought for producing micro-channels in copper. The other attributes associated with the micro-channels have also been deeply investigated including the inter-channels fin height (IFH), inter-channels fin radius (IFR) and the micro-channels width (MCW). The results reveal that the inter-channels fin is the most critical feature to control during the wire electrical discharge machining (WEDM) of copper. Four types of fin shapes have been experienced, including the fins: broken at the top end, deflected at the top end, curled bend at the top, and straight with no/negligible deflection. |
| first_indexed | 2024-12-20T22:42:25Z |
| format | Article |
| id | doaj.art-1225913a148249f183820f9789340851 |
| institution | Directory Open Access Journal |
| issn | 2072-666X |
| language | English |
| last_indexed | 2024-12-20T22:42:25Z |
| publishDate | 2020-02-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj.art-1225913a148249f183820f97893408512022-12-21T19:24:26ZengMDPI AGMicromachines2072-666X2020-02-0111217310.3390/mi11020173mi11020173WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels: A Prerequisite for the High Heat-Transfer RateNaveed Ahmed0Mohammad Pervez Mughal1Waqar Shoaib2Syed Farhan Raza3Abdulrhman M. Alahmari4Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, PakistanDepartment of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, PakistanDepartment of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, PakistanDepartment of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore 54890, PakistanRaytheon Chair for Systems Engineering, Advanced Manufacturing Institute, King Saud University, Riyadh 11421, Saudi ArabiaTo get the maximum heat transfer in real applications, the surface area of the micro-features (micro-channels) needs to be large as possible. It can be achieved by producing a maximum number of micro-channels per unit area. Since each successive pair of the micro-channels contain an inter-channels fin, therefore the inter-channels fin thickness (IFT) plays a pivotal role in determining the number of micro-channels to be produced in the given area. During machining, the fabrication of deep micro-channels is a challenge. Wire-cut electrical discharge machining (EDM) could be a viable alternative to fabricate deep micro-channels with thin inter-channels fins (higher aspect ratio) resulting in larger surface area. In this research, minimum IFT and the corresponding machining conditions have been sought for producing micro-channels in copper. The other attributes associated with the micro-channels have also been deeply investigated including the inter-channels fin height (IFH), inter-channels fin radius (IFR) and the micro-channels width (MCW). The results reveal that the inter-channels fin is the most critical feature to control during the wire electrical discharge machining (WEDM) of copper. Four types of fin shapes have been experienced, including the fins: broken at the top end, deflected at the top end, curled bend at the top, and straight with no/negligible deflection.https://www.mdpi.com/2072-666X/11/2/173wire electrical discharge machining (wedm)discharge energymicro-channelsdeflectioncopperfin-thicknessfin-radiusfin-heightsurface areaheat transfer |
| spellingShingle | Naveed Ahmed Mohammad Pervez Mughal Waqar Shoaib Syed Farhan Raza Abdulrhman M. Alahmari WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels: A Prerequisite for the High Heat-Transfer Rate Micromachines wire electrical discharge machining (wedm) discharge energy micro-channels deflection copper fin-thickness fin-radius fin-height surface area heat transfer |
| title | WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels: A Prerequisite for the High Heat-Transfer Rate |
| title_full | WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels: A Prerequisite for the High Heat-Transfer Rate |
| title_fullStr | WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels: A Prerequisite for the High Heat-Transfer Rate |
| title_full_unstemmed | WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels: A Prerequisite for the High Heat-Transfer Rate |
| title_short | WEDM of Copper for the Fabrication of Large Surface-Area Micro-Channels: A Prerequisite for the High Heat-Transfer Rate |
| title_sort | wedm of copper for the fabrication of large surface area micro channels a prerequisite for the high heat transfer rate |
| topic | wire electrical discharge machining (wedm) discharge energy micro-channels deflection copper fin-thickness fin-radius fin-height surface area heat transfer |
| url | https://www.mdpi.com/2072-666X/11/2/173 |
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